IP Library › Granted Patent US 8,822,355
Granted Patent B2
US 8,822,355 · App. 11/087,354 · Granted Sep 2, 2014

Fire resistant composite material and fabrics made therefrom

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Quick Facts
Patent No.
US 8,822,355
App. No.
11/087,354
Granted
Sep 2, 2014
Kind
B2
Abstract

The present invention relates to fire resistant composite materials and to fire resistant fabric materials and mattresses made therefrom. The composite materials include (a) a substrate selected from the group consisting of cotton, rayon, lyocell and blends thereof; and (b) a coating consisting essentially of water, ammonium polyphosphate, urea formaldehyde binder material, prefarbricated glass microcells, acrylic latex binder, ammonium lauryl sulfate surfactant, thickener material, a second surfactant, surfactant-generated microcells, a catalyst and starch. The binder materials bond the ammonium polyphosphate, prefarbricated microcells, thickener material, surfactants, surfactant-generated microcells, catalyst and starch together and to the substrate such that the substrate is coated with the coating.

Claims (15)

1. A composite material comprising:

(a) a substrate selected from the group consisting of cotton, rayon, lyocell, and blends thereof; and

(b) a coating consisting essentially of water, about 35% to about 45% by weight ammonium polyphosphate, about 3.0% to about 7.0% by weight urea formaldehyde binder, about 2.5% to about 10% by weight prefabricated glass microcells, about 18% to about 25% by weight acrylic latex binder, about 0.1% to about 1.0% by weight ammonium lauryl sulfate first surfactant and first surfactant-generated microcells, about 0.1% to about 0.5% by weight thickener material, about 2.5% to about 8.0% by weight second surfactant and second surfactant-generated microcells, about 0.1% to about 1.0% by weight catalyst, and about 0.5% to about 2.5% by weight starch;

wherein said binder materials bond the ammonium polyphosphate, prefabricated glass microcells, ammonium lauryl sulfate first surfactant, first surfactant-generated microcells, thickener material, second surfactant, second surfactant-generated microcells, catalyst, and starch together and to the substrate such that the substrate is coated with said coating.

2. The composite material according to claim 1 wherein said substrate is planar and is coated on one side with said coating.

3. The composite material according to claim 1 wherein said substrate is planar and is coated on both sides with said coating.

4. The composite material according to claim 1 , 2 or 3 , wherein said material further includes a water repellent material.

5. The composite material according to claim 1 , 2 or 3 wherein said material further includes an antifungal material.

6. The composite material according to claim 1 , 2 or 3 wherein said material further includes an antibacterial material.

7. The composite material according to claim 1 , 2 or 3 wherein said material further includes a surface friction agent.

8. The composite material according to claim 1 , 2 or 3 wherein said material further includes a flame retardant material.

9. The composite material according to claim 1 , 2 or 3 wherein said material further includes an algaecide.

10. The composite material according to claim 1 , 2 or 3 wherein said material is colored with dye.

11. A mattress fabric comprising a decorative fabric and the composite material according to claim 1 .

12. A mattress comprising the mattress fabric of claim 11 .

Assignments (6)
SECURITY INTEREST Recorded Sep 23, 2021
From: BMIC LLC; ELKCORP; ELK COMPOSITE BUILDING PRODUCTS, INC.; ELK PREMIUM BUILDING PRODUCTS, INC.; HBP ACQUISITION LLC; GAF ENERGY LLC; SIPLAST, INC.; SPECIALTY GRANULES INVESTMENTS LLC
To: DEUTSCHE BANK AG NEW YORK BRANCH
Reel/Frame 057572/0607 →
RELEASE OF SECURITY INTEREST Recorded Nov 5, 2011
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
To: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK PERFORMANCE NONWOVEN FABRICS, INC.; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO., INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, L.P.; NELPA, INC.
Reel/Frame 027180/0400 →
RELEASE OF SECURITY INTEREST Recorded Nov 5, 2011
From: DEUTSCHE BANK AG NEW YORK BRANCH, AS COLLATERAL AGENT
To: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK PERFORMANCE NONWOVEN FABRICS, INC.; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO., INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, L.P.; NELPA, INC.
Reel/Frame 027180/0435 →
SECURITY AGREEMENT Recorded Jun 22, 2007
From: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO. INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, LP; NELPA, INC.; ELK PERFORMANCE NONWOVEN FABRICS, INC.
To: DEUTSCHE BANK TRUST COMPANY AMERICAS
Reel/Frame 019466/0247 →
SECURITY AGREEMENT Recorded Jun 22, 2007
From: ELKCORP; ELK PREMIUM BUILDING PRODUCTS, INC.; ELK CORPORATION OF AMERICA; ELK CORPORATION OF ALABAMA; ELK CORPORATION OF TEXAS; ELK CORPORATION OF ARKANSAS; ELK PERFORMANCE NONWOVEN FABRICS, INC.; ELK COMPOSITE BUILDING PRODUCTS, INC.; RGM PRODUCTS, INC.; RIDGEMATE MANUFACTURING CO. INC.; ELK SLATE PRODUCTS, INC.; ELK VERSASHIELD BUILDING SOLUTIONS, INC.; ELK TECHNOLOGY GROUP, INC.; CHROMIUM CORPORATION; ELK TECHNOLOGIES, INC.; MIDLAND PATH FORWARD, INC.; LUFKIN PATH FORWARD, INC.; ELK GROUP, INC.; ELK GROUP, LP; NELPA, INC.
To: DEUTSCHE BANK AG NEW YORK BRANCH
Reel/Frame 019466/0270 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 14, 2005
From: AHLUWALIA, YOUNGER
To: ELKCORP
Reel/Frame 016689/0159 →